Design And Realization Of Shearer Condition Monitoring System Based On Wireless Sensor Networks

Coal is one of China's primary energy, and coal mining is a major event relating to the national economy. With the progress of science and technology, mine production is becoming increasingly automatic and mechanical, which promote the efficient production of coal mines. But it also raises a problem that the harsh mine environment easily lead to the shearer to malfunction, affecting the normal operation of the mine and bringing huge economic losses to the state. So it is imminent to monitor the running status of the shearer. The traditional wire monitoring system has some drawbacks such as poor flexibility, and it is difficult to meet the monitoring requirements of the shearer.Wireless Sensor Networks(WSN) is a hot research field, which has got much attention in the international arena. It has been named first by the "MIT Technology Review" in the top ten emerging technologies. The research of Wireless Sensor Networks be applied to the mine safety monitoring is still in the initial stage, and WSN is mainly used in coal mine environmental monitoring and personnel orientation, etc. It is of great significance applying Wireless Sensor Networks to monitor shearer operating status. Its main advantage is no need for wiring in Wireless transmission, and it has many desired properties, such as flexible layout. Monitoring shearer operating status by Wireless Sensor Networks, we can conveniently and quickly learn its health condition to avoid any accidents effectively.The ZigBee technology with low-cost and low-power was chose to design shearer monitoring system through the comparison of several mainstream wireless communications technology. On the basis of theoretical studies, combined with the practical application background of shearer, a overall system solution was designed, including data collection, data transmission and on-line monitoring. The MCU MSP430F5438 controls three-axis accelerometer(ADXL345) and temperature sensor(DS18B20) to collect the vibration and temperature signals, and the radio frequency chip(CC2530) to complete wireless transmission and reception of data, finally it communicates with the host computer by RS232.In this paper, following tasks have been accomplished, including the design of hardware circuit for coordinator node and end device, and the software design of wireless sensor networks on the IAR. Program of ADXL345, DS18B20 and CC2530 chip was completely developed. The node can format networks successfully and accomplish the mission of collection and wireless transmission about temperature and vibration data. A monitoring system is also designed by LabVIEW software so that we can visually monitor the running status of the shearer. This system meets the requirements of the real-time control, the trends show, data storing and reading, the accident reports, etc. which makes it is convenient for managers to make decisions.Finally, we conducted a series of test to prove the effectiveness of data acquisition module and ZigBee wireless module of the shearer condition monitoring system, including the test of the communication distance, signal strength and network capabilities. The testing result indicates that the system based on ZigBee technology basically realized the acquisition and wireless transmission of the vibration and temperature signals, it works well and achieves the desired objectives.